Appendix IB. Course Syllabi

IE 348 Solidification Processes

Description: Theory, applications, and quality issues related metal casting, welding, polymer processing, and other solidification processes. Uses of CAD and process modeling software.

Prerequisites: IE 248

Books:

1. Materials and Processes in Manufacturing, 8^th edition, DeGarmo, Black & Kosher (1997).
2. IE 348 Laboratory Manual, Peters (1999).
3. IE 348 Class Notes, Peters (1999).
4. Reference books (will be) on reserve in Parks Library. These books will be a valuable resource for the laboratory reports.

Objectives:
Learn the fundamentals of solidification processes, material composition and cooling rates and the effect on material properties. Also, learn the advantages and limitations of these processes, and the molding and tooling required for each process. Comparison to the machining processes learned previously, and how theses processes effect the subsequent machining. Learn the use of CAD, particularly solid models, and their application to process modeling. Be able to effectively work as a group to conduct the design projects and the laboratory experiments investigating the manufacturing processes and material properties measurement.

Topics:

1. Overview of solidification processes and the relationship to material removal processes
2. Review of engineering materials, properties, and how it relates to the manufacturing processes
3. Welding processes: GTAW, GMAW, SMAW, FCAW, SSFCAW, SAW
4. Distortion of welding and dimensional capability
5. Joint design for joining processes
6. Casting processes: lost foam, investment, die, green sand, vacuum, shell, chemically bonded sand, permanent mold
7. Dimensional capabilities of casting
8. Designing for casting
9. Non destructive evaluation techniques
10. Electronic manufacturing
11. Polymer processing
12. Powder metallurgy
13. Pattern tooling requirements for all processes covered

Class/Laboratory Schedule:
The class meets 2 times a week for 50 minutes. Several teaching strategies are employed as appropriate. The classroom activities are supported by a semi-note packet to allow more time for discussion of the topics. There are 2 in class exams, plus the final, and approximately 10 quizzes or short assignments. The laboratory (which accounts for 40% of the grade), meets in sections of <= 16 students, once each week for 110 minutes. Approximately half of the lab sessions are dedicated to laboratory experiments. For most of the experiments, the students conduct the experiment and operate the equipment with minimal direction and oversight. The other sessions are used for engineering drawing using solid modeling software and work on their manufacturing analysis project.

Contribution of Course to Meeting Professional Component:
The strong laboratory component of this class supports several professional components including conducting experiments, analysis of results, written communication and working as a team. The course also includes modern engineering tools and information and techniques towards engineering problem solving.

Relationship of Course to Program Objectives:
This course supports the objective of being able to integrate the engineering and business processes of an enterprise, particularly by understanding the impact of design and manufacturing on product cost.

How Assessed:
In addition to the end of the semester evaluations conducted by the University, the students in APM coordinate course evaluations about mid semester. I also conduct ‘5 minute’ evaluations when I feel their may be problems or am just curious of the student’s perception of the class.

Actions to Improve the Course:
Based on the feedback from the students, and knowledge I gain from working with industry, the course is constantly updated. At the most basic level, I am constantly gaining more examples, many of them actual parts, that I share with the class as appropriate. Laboratory exercises have gone through a tremendous change over the past 3 years, with plans for additional additions and improvements.

Prepared by: Frank Peters 12/20/99